Method of making a vacuum cleaner hose assembly

ABSTRACT

A vacuum hose is provided having a plurality of reinforcing wires in the form of electrical conductors which are made as an integral part of the hose and each conductor has electrical components fixed to its opposite ends. A pair of hose connectors is provided at opposite ends of the hose end formed substantially as an integral part thereof to define an assembly with each hose connector having associated electrical components embedded therein and providing the sole support therefor.

to States Patent 1 Wickham et a1.

[54] METHOD OF MAKING A VACUUM CLEANER HOSE ASSEMBLY [76] Inventors:William T. Wickham, 930 Brunswick Dr., Waynesville, NC. 28786; FrankBrown, 5556 Viewpoint Dr., Dayton, Ohio 45459; Donald L. Kleykamp, 868Heincke Dr., West Carrollton, Ohio 45449; Otto Kossuth, 5936 DeanmontPl., Dayton, Ohio 45459 [22] Filed: July 28, 1971 [21] Appl. No.1176,372

Related US. Application Data [62] Division of Ser. No. 848,272, Aug. 7,1969.

[52] US. Cl ..29/628, 29/629 [51] Int. Cl. .1101! 43/00 [58] Field ofSearch ..29/629, 628, 630 A;

[56] References Cited UNITED STATES PATENTS 2,727,299 12/1955 Klumpp,Jr...29/629X FOREIGN PATENTS OR APPLICATIONS 1,297,597 ll/1962 France..15/377 Primary Examiner-Charles W. Lanham Assistant Examiner-James R.Duzan AttorneyReuben Wolk [57] ABSTRACT A vacuum hose is provided havinga plurality of reinforcing wires in the form of electrical conductorswhich are made as an integral part of the hose and each conductor haselectrical components fixed to its opposite ends. A pair of hoseconnectors is provided at opposite ends of the hose end formedsubstantially as an integral part thereof to define an assembly witheach hose connector having associated electrical components embeddedtherein and providing the sole support therefor.

5 Claims, 13 Drawing Figures PATENTEUMAY 22 i973 INVENTORS g v un DONALDKLEYKAMP v I V BY 56 55 W M;

THEIR ATTORNEY PATENTEDMM'ZZ ms SHEET 2 BF 3 FlG -8 U S O T S OE N L mmmV wm m w m m s V UE ND E SH TNE wmmmmmnx 5am mmw mFawm Am wm m m N A mhmm 0mm i O VIIE m C M N MLELY T 50 N DTI E E O m DA% WAG E T W D TO S AAER M O MXCQR L T HO SEE 0 I LAO L NL F POL O H N ECH P OHE C INVENTORSWILLIAM T WICKHAM FRANK BROWN DONALD L. KLEYKAMP OTTO KOSSUTH BY M THEIRATTORNEY 1 IIIIENTEIIIIAY22 mrs SHEET 3 IIF 3 INVENTORS WILLIAM T.WICKHAM FRANK BROWN DONALD L. KLEYKAMP OTTO KOSSUTH THEIR ATTORNEYMETHOD OF MAKING A VACUUM CLEANER HOSE ASSEMBLY This application is adivision of United States application Ser. No. 848,272, filed Aug. 7,1969.

BACKGROUND OF THE INVENTION Many so-called tank or canister type vacuumcleaners in current use have a vacuum hose assembly connected to a tankat one end and cleaning tool at the other end which often comprises acleaning brush powered by an electric motor. There have been numerousvacuum hose assemblies proposed heretofore for providing electricalpower to and controlling such motor; however, these previously proposedassemblies utilize a large number of component parts, are difficult andexpensive to assemble and maintain, and are thus generallyunsatisfactory.

SUMMARY This invention provides an improved vacuum cleaner hoseassembly, and method of making same, for use with a canister-type vacuumcleaner, or the like, which is of simple and economical construction,has vacuum hose connectors at its opposite ends which are, in essence,provided as an integral part of the vacuum hose comprising suchassembly, and has electrical means or devices embedded in each hoseconnector substantially as an integral part thereof with the hoseconnectors providing the sole support for the electrical devices. Thisinvention also provides a hose assembly which has integral control meansfor controlling an electric motor provided on a cleaning tool used inassociation with such hose assembly wherein the control means is alsoembedded in one of the hose connectors.

Other details, uses, and advantages of this invention will becomeapparent as the following description of the exemplary embodimentsthereof presented in the accompanying drawings proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings show presentexemplary embodiments of this invention, in which FIG. 1 is aperspective view with parts in cross section and parts broken awayillustrating a vacuum cleaning apparatus together with an exemplaryvacuum hose assembly of this invention;

FIG. 2 is a greatly enlarged cross-sectional view particularlyillustrating a female hose connector provided at one end of the hoseassembly;

FIG. 3 is a greatly enlarged fragmentary crosssectional viewillustrating a male hose connector at the opposite end of the hoseassembly;

FIG. 4 is a cross-sectional view illustrating a dualpurpose electricalconnector which may be optionally used in the hose assembly of FIG. 1 asa female connector;

FIG. 5 is a cross-sectional view illustrating the dualpurpose connectorof FIG. 4 used as a male connector;

FIG. 6 is a perspective view with parts shown schematically and otherparts broken away particularly illustrating an exemplary apparatus whichmay be used to make the hose assembly of this invention;

FIG. 7 is an enlarged plan view of a typical lower mold comprising theapparatus of FIG. 6 and also illustrating the manner of placing a vacuumhose in position therein to form hose connectors as an integral part ofits opposite ends;

FIG. 8 is a process chart particularly highlighting certain method stepswhich may be utilized to form the hose assembly of this invention;

FIG. 9 is a fragmentary perpsective view particularly illustratinganother embodiment of a hose assembly having one embodiment of a controlswitch provided as an integral part of a hose connector at one end ofsuch hose assembly;

FIG. 10 is a fragmentary cross-sectional view with certain parts shownin elevation and taken essentially on the line 1010 of FIG. 9;

FIG. 11 is an electrical wiring diagram illustrating the manner ofelectrically connecting the switch of FIGS. 9 and 10 in its electricalcircuit;

FIG. 12 is a fragmentary cross-sectional view similar to FIG. 10 andillustrating still another embodiment of a hose assembly having anotherembodiment of an integral control switch; and

FIG. 13 is an electrical wiring diagram similar to FIG. 11 andillustrating the manner of electrically connecting the switch of FIG. 12in its electrical circuit.

DESCRIPTION OF ILLUSTRATED EMBODIMENTS Reference is now made to FIG. 1of the drawings which illustrates an exemplary vacuum cleaning apparatus20 which utilizes one embodiment of the hose assembly 21 of thisinvention. The apparatus 20 has a canister or tank 22 provided with asuitable vacuum tube 23 extending outwardly therefrom. The apparatus 20is provided with electrical power for operating its vacuum unit in aconventional manner and has a female receptacle 24 mounted on its tank22 and the receptacle 24 is used to supply power through electricalmeans provided in the hose assembly 21 of this invention to an electricmotor 25 comprising the terminal end of a cleaning instrument 26 whichis operatively connected to the hose assembly 21.

The apparatus 20 has an electrical cord 27 provided with a male fitting28 at one end and a female fitting 30 at its opposite end and the cord27 is used to provide an electrical connection between the femaleconnector 24 and one end of the hose assembly 21. The apparatus 20 alsohas an electrical cord 32 which has one end electrically connected tothe motor 25 in the cleaning instrument 26 and the cord 32 has a maleconnector 33 which is electrically connected to an associated femaleconnector in the end of the hose assembly 21 which is remote from thetank 22.

The hose assembly 21 is comprised of a flexible vacuum hose 34 which hasreinforcing wires 35 and 36 suitably provided substantially as anintegral part thereof and in a manner well known in the art and thereinforcing wires also serve as electrical conductors. The wires orconductors 35 and 36 are insulated by tubular jackets or sleeves 40 and41 respectively of insulating material.

Each wire 35 and 36 has a pair of electrical connector means or devicesfixed to its opposite ends and in this example of the invention eachwire 35 and 36 has a female connector 42 fixed to one end thereof and amale connector 43 fixed to its opposite end. The male connectors 43 areconnected to female fittings 30 of cord 27 and the male connector 33 ofcord 32 is plugged in female connectors 42 so that once connector 28 isplugged into receptacle 24 an electrical circuit is completed to themotor 25.

The hose assembly 21 has a pair of hose connectors 44 and 45 fixed toits opposite ends and each hose connector is provided substantially asan integral part of the vacuum hose 34. In particular, each hoseconnector 44 and 45 is preferably formed in position, as by injectionmolding, for example, to thereby define a streamlined and compact hoseconnector in each instance which is fixed to the vacuum hose 34 and hasassociated electrical connector means embedded therein so as to providethe sole support for such connector means and in a manner to bedescribed in detail subsequently.

As seen in FIG. 2 of the drawings the hose connector 44 is formed inposition in a fixed manner around an associated end 46 of the vacuumhose 34 and a pair of female connectors 42 are suitably fixed as bysoldering, or the like, to the ends of the conductors 35 and 36 andembedded in position. The female connectors 42 are in a protectedposition indicated at 47 yet are readily accessible through an accessopening 48 provided in the connector 44 during the forming thereof.

The hose connector 45 is also suitably formed in position around theopposite end 50 of the vacuum hose 34 and a pair of male connectors orpins 43 are suitably fixed to the ends of wires 35 and 36. The pins 43are in a protected position as indicated at 51 and are readilyaccessible through an access opening 52.

The vacuum hose 34 is preferably made of a plastic material which isalso an electrical insulator and the insulating sleeves 40 and 41provided on the wires 35 and 36 respectively are made of a plasticmaterial which is compatible with the plastic material used to form hose34 so that the sleeves 40 and 41 and hence wires 35 and 36 may be easilybonded in position essentially as an integral part of the vacuum hose34. The hose connectors 44 and 45 are preferably made of a thermoplasticmaterial which is easily formed around associated ends of vacuum hose 34to define connectors 44 and 45 and the thermoplastic material used tomake hose connectors 44 and 45 is also an electrical insulatingmaterial.

The female members 42 and male pins 43 illustrated in FIGS. 2 and 3 areshown as being soldered in position. However, the hose assembly 21 maybe provided with dual-purpose roughly tubular members designated by thereference numeral 53 and illustrated in FIGS. 4 and 5. Each member 53may be attached to an associated conductor by soldering, or the like;however, member 53 is particularly adapted to be mechanically compressedagainst an associated wire to provide both a mechanical and anelectrical connection and each member 53 may be used as either a male orfemale connector.

In particular, it will be seen from FIG. 4 that a reduced diametercylindrical portion 54 of member 53 is crimped around an associated wireas indicated at 55 to fix the member 53 to such wire so that a largerdiameter tubular portion 56 of member 53 will have its tubular insidesurface 57 unobstructed so that it may be used as a female receptacle.It will be appreciated that the inside surface 57 corresponds inconfiguration and size to the inside surface 58 of the female receptacle42.

To use the member 53 as a male pin the crimping action is again achievedin a similar manner as illustrated at 55 with the exception that theelectrical wire extends through the larger diameter tubular portion 56and terminates short of the'terminal outer end of the reduced diameterportion 54, see FIG. 5. It will be appreciated that the outside surfaceof reduced diameter portion 54 corresponds in configuration and size tothe outside surface of the pin 43.

Thus it is seen that the member 53 may be suitably fixed in position toserve as either a male or female electrical connector depending upon themanner in which the electrical wire is fixed therein. In addition, theadded length of each member 53 enables it to be embedded in position ina stronger manner in an associated hose connector.

The hose assembly 21 may be made utilizing any suitably technique;however, it is preferably made utilizing the method steps essentially aspresented in FIG. 8 of the drawings and certain ones of such methodsteps may be carried out using an apparatus of the character presentedin FIGS. 6 and 7.

The apparatus illustrated in FIG. 6 comprises an injection moldingapparatus 60 which has a base 61 which carries a horizontally supportedworktable 62 which may be reciprocated back and forth on the base. Theworktable 62 carries mold means shown in this example as a pair of lowermolds 63 of substantially identical construction and each mold 63 isadapted to receive opposite ends of a vacuum hose 34 therewithin as seenin FIG. 7.

The apparatus 60 has an upper mold 64 which is adapted to be placed inposition over eachlower mold 63 in an alternating manner and with theupper mold 64 positioned over a mold 63 the molds cooperate to define amold assembly 65 and a pair of mold cavities around opposite ends of thevacuum hose and such cavities define the configurations of hoseconnectors 44 and 45. A suitable plastic material such as athermoplastic material is then injected under heat and pressure intosuch mold cavities and suitably cooled to define the hose connectors 44and 45 substantially as an integral part of the vacuum hose 34.

The apparatus 60 also has a cooling system indicated at which includes acooling unit 71 which contains a cooling fluid which is circulated by apump 72 driven by a motor 73. A selector valve 74 is provided which hasa line 75 connected to one end of each of the lower molds 63 and areturn line 76 is provided from the opposite end of each lower mold 63to the unit 71. During the time that a thermoplastic material isinjected into a particular mold assembly 65 to define integral hoseconnectors 44 and 45 the selector valve is positioned so that coolantwill not flow through the lower mold cavity of such assembly. However,once the injection molding has been completed the mold remains closedand cooling fluid is circulated through the particular assembly 65 forapproximately one minute to chill the thermoplastic material. The uppermold 64 is then moved away and the worktable 62 is moved so as toposition the other lower mold 63 with its vacuum hose 34 in positionbeneath the upper mold 64 so that upon moving the upper mold 64 inposition the injection molding procedure may be repeated to form anotherhose assembly 21.

The worktable 62 is easily shuttled on the base 61 so that during thetime that hose connectors 44 and 45 are being simultaneously injectionmolded and chilled at opposite ends of one vacuum hose 34 loaded in onelower mold 63 another vacuum hose 34 is being placed or loaded andsuitably supported in position on the other lower mold 63 whereby theapparatus 60 enables efficient forming of hose assemblies 21.

The thermoplastic material is injected into each mold assembly 65 in aknown manner and excellent results have been obtained by heating vinylmaterials, such as polyvinyl chloride for example, to a temperatureranging roughly between 380 and 410 Fahrenheit. In addition,satisfactory results have been obtained by injecting the thermoplasticmaterial into the mold cavity at pressures of roughly 550 psig.

Each lower mold 63 and the upper mold 64 are constructed to enable bothends of a vacuum hose 345 to be suitably supported in position. Once thethermoplastic material is introduced into the assembly 65 defined bymolds 63 and 64 the hose connectors 44 and 45 are formed simultaneouslywhereby the vacuum cleaner assembly 21 is essentially a one-piececonstruction, even though comprised of a number of parts, and such onepiece construction cannot be taken apart except by practicallydestroying it. Obviously, this makes an assembly which has a longoperating life, is safe to use, and is essentially tamper-proof.

Another exemplary embodiment of a vacuum hose assembly of this inventionis illustrated in FIGS. 9, 10, and 11 of the drawings. The hose assemblyof FIGS. 9-11 is very similar to the hose assembly 21; therefore, suchhose assembly will be designated by the reference numeral 21A and partsof the hose assembly 21A which are very similar to corresponding partsof the hose assembly 21 will be designated by the same reference numeralas in the hose assembly 21, also followed by the letter designation Aand not described again. Only those component parts which aresubstantially different from corresponding parts of the hose assembly 21will be designated by a new reference numeral also followed by theletter designation A and described in detail.

The hose assembly 21A differs from the hose assembly 21 only in that ithas an electrical control device 80A embedded in its hose connector 44A.The electrical control device 80A is in the form of control switch whichis electrically connected in series in the line 35A and has an foffposition 81A and integral means shown as a potentiometer 82A capable ofproviding a substantially infinite number of electrical outputstherefrom for controlling a motor 25A comprising an associated cleaningtool assembly 26A.

The potentiometer has a rotatably arm 83A which is electricallyconnected to one end portion of the conductor 35A and a variableresistor 84A which is connected to the opposite end portion of theconductor 35A whereupon by moving the arm 83A from the of position andinto contact with the variable resistor B4A the resistance in the systemmay be varied in a known manner to provide substantially infinite speedcontrol for the motor 25A. As best seen in FIG. 10, the switch 80A has ashaft 85A extending outwardly therefrom and the shaft is operativelyconnected to the arm 83A at its inner end and has knurled knob 86Aattached thereto at its outer end to thereby enable an operator toeasily adjust the device 80A. The hose connector 44A is formed as anintegral part of the vacuum hose 34A as previously explained and withthe switch being integrally embedded in connector 44A it provides thesole support as well as electrical insulation and protection for suchswitch.

Another exemplary embodiment of this invention is illustrated in FIGS.12 and 13 of the drawings. The hose assembly illustrated in FIGS. 12 and13 is very similar to the hose assembly 21; therefore, such hoseassembly will be designated generally by the reference numeral 218 andparts thereof which are very similar to corresponding parts of the hoseassembly 21 will be designated by the same reference numeral as in thehose assembly 21 also followed by the letter designation B and notdescribed again in detail. As previously, only substantially differentcomponent parts will be given new reference numerals also followed bythe letter designation B and described in detail.

The hose assembly 218 utilizes an electrical switch 90B which issuitably embedded and formed essentially as an integral part of hoseconnector 44B whereby the hose connector 44B provides the sole supportfor switch 908 as well as electrical insulation and protection therefor.The switch 90B has an actuating lever 91B which is normally in an ofposition and by actuating the lever 91B the switch may be moved incontact with either a spring-loaded pin 928 or a spring-loaded pin 93Bsuitably supported in an associated housing 948.

Upon actuating the lever 91B so that it urges pin 93B inwardly anelectrical connection is provided through an integral resistor 95B andthereby provides a reduced current flow to operate the associated motor258 at low speed. Upon actuating the lever 918 so that it urges the pin92B inwardly an electrical connection is provided which bypasses theresistor 95B whereupon the motor 25B is operated at high speed. Thebutton or lever 91B is in the form of a toggle arrangement of knownconstruction and once actuated to operate the motor 25B at either low orhigh speed by depressing pin 93B or 92B respectively the particular pinremains depressed until the lever is again actuated to either move it tothe off position or into contact with the other pm.

In this example of the invention the switches A and B are shown as beingembedded in associated integral connectors 44A and 44B respectively andsuch connectors define the end of their hose assembly which is arrangedopposite the associated tank or canister. However, it will beappreciated that, if desired, switches 80A and 90B may be provided inthe ends of their hose assembly arranged adjacent their canister andhence in ends 45A and 45B respectively.

Any suitable plastic material may be used to form the hose connectorscomprising opposite ends of each hose assembly of this invention;however, it is preferable that a thermoplastic material such aspolyvinyl chloride, polyethylene, and the like, be utilized and injectedmolded in position to simultaneously form and fix the hose connectors inposition at the opposite ends of an associated vacuum hose as well asembed the associated electrical devices whether they be male or femaleconnectors or electrical switches whereby each hose assembly of thisinvention is formed in a simple, efficient, and low-cost manner.

The thermoplastic material which is selected to make the integral hoseconnectors should also be compatible with the flexible plastic materialwhich is used to define the vacuum hose to assure that the hoseconnectors are formed at opposite ends of the vacuum hose essentially asan integral part thereof and such thermoplastic material serves as amatrix within which associated electrical components are embedded in ahigh strength and electrically insulated manner.

The apparatus 60 and method of this ivention have been describedprimarily in connection with the hose assembly 21. However, it is to beunderstood that the molds of such apparatus may be suitable modified ina manner well known in the art to enable forming of hose assemblies 21Aand 21B in a similar manner as assembly 21. In addition, the method offorming hose assemblies 21A and 21B is substantially identical to themethod of forming hose assembly 21.

While present exemplary embodiments of this invention and methods ofpracticing the same have been illustrated and described, it will berecognized that this invention may be otherwise variously embodied andpracticed by those skilled in the art.

What is claimed is:

1. A method of making a unitary vacuum cleaner hose assembly having aplurality of axially spaced electrically conducting reinforcing coilswith axially alternating turns terminating in outwardly extending ends;comprising the steps of affixing electrical means to at least one end ofsaid coils, placing and supporting said end within a mold cavity,introducing a thermoplastic material into said cavity under heat andpressure, and forming an integral hose connector on said end to embedand support said end and means.

2. The method of claim 1 including the steps of affixing a maleelectrical connector means to one end of said coils, affixing a femaleelectrical connector means to the other end of said coils, and embeddingsaid means within their respective hose connectors.

3. The method of claim 1 including the steps of affixing an electricalcontrol device to one end of said coils, and embedding said devicewithin said connector.

4. The method of claim 3 in which said device is an electrical controlswitch.

5. The method of claim 1 including the steps of affixing electricalmeans to both ends of said coils, placing and supporting both ends ofsaid coils and corresponding means within adjacent mold cavities, andsimultaneously forming integral hose connectors on said ends to embedand support said ends and corresponding means.

222%? UNITED STATES PATENT FFKCE CERTIFICATE OF CETl Patent No. ,7 3, 97Dated May 22, 1973 William T. Wickham, Frank Brown, Donald L, Kleykamp,Otto Kossuth It is certified that error appears in the above-identifiedpetent and that said Letters Patent are hereby corrected as shown below:

On the title page between "[76]" and "[22}" insert the following:

--- [73] Assignee: Dayco Corporation, Dayton, Ohio Signed and sealedthis 12th clay of February 1974 (SEAL) Attest:

EDWARD M.FLETCHER,JR. C. MARSHA Attesting' Officer miSi0 1 :P g Pat t

1. A method of making a unitary vacuum cleaner hose assembly having a plurality of axially spaced electrically conducting reinforcing coils with axially alternating turns terminating in outwardly extending ends; comprising the steps of affixing electrical means to at least one end of said coils, placing and supporting said end within a mold cavity, introducing a thermoplastic material into said cavity under heat and pressure, and forming an integral hose connector on said end to embed and support said end and means.
 2. The method of claim 1 including the steps of affixing a male electrical connector means to one end of said coils, affixing a female electrical connector means to the other end of said coils, and embedding said means within their respective hose connectors.
 3. The method of claim 1 including the steps of affixing an electrical control device to one end of said coils, and embedding said device within said connector.
 4. The method of claim 3 in which said device is an electrical control switch.
 5. The method of claim 1 including the steps of affixing electrical means to both ends of said coils, placing and supporting both ends of said coils and corresponding means within adjacent mold cavities, and simultaneously forming integral hose connectors on said ends to embed and support said ends and corresponding means. 